Curved catheter and methods for making same

ABSTRACT

A pre-curved catheter tube of a catheter assembly or other elongate medical device and methods for forming such a device using a heating procedure is disclosed. Pre-curving of the catheter tube is desirable to impart to the catheter assembly a desired positional configuration when the catheter assembly is inserted into a patient. The heating procedure may include heat sterilization procedures commonly used to sterilize medical devices prior to use. In one embodiment, therefore, a catheter assembly is disclosed, comprising an elongate catheter tube defining at least one lumen, and a tube constraint. The tube constraint is included with the catheter assembly and is configured to temporarily constrain the catheter tube in a curved configuration during a heating procedure of the catheter assembly so as to permanently form the catheter tube in the curved configuration after the heating procedure is complete and the catheter tube is released from the tube constraint.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 61/751,682, filed Jan. 11, 2013, and titled “Systems and Methods for Forming A Pre-Curved Catheter,” which is incorporated herein by reference in its entirety.

BRIEF SUMMARY

Briefly summarized, embodiments of the present invention are directed to a pre-curved catheter tube of a catheter assembly or other elongate medical device and methods for forming such a device using a heating procedure. Pre-curving of the catheter tube is desirable to impart to the catheter assembly a desired positional configuration when the catheter assembly is inserted into a patient. The heating procedure may include heat sterilization procedures commonly used to sterilize medical devices prior to use.

In one embodiment, a catheter assembly is disclosed, comprising an elongate catheter tube defining at least one lumen, and a tube constraint. The tube constraint is included with the catheter assembly and is configured to temporarily constrain the catheter tube in a curved configuration during a heating procedure of the catheter assembly so as to permanently form the catheter tube in the curved configuration after the heating procedure is complete and the catheter tube is released from the tube constraint.

Examples of catheter assemblies that can benefit from the present disclosure include CVC, PICC, dialysis, peripheral IV and other catheters, though the principles to be described herein can be applied to catheters and elongate medical devices of a variety of configurations.

These and other features of embodiments of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of embodiments of the invention as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

A more particular description of the present disclosure will be rendered by reference to specific embodiments thereof that are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. Example embodiments of the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIGS. 1A and 1B are various views of a catheter assembly including a curved catheter tube according to one embodiment;

FIG. 2 shows views of a bifurcation portion of the catheter assembly of FIGS. 1A and 1B including a tube constraint according to one embodiment;

FIGS. 3A and 3B show the bifurcation portion of FIG. 2 in multiple configurations;

FIGS. 4A and 4B show various views of a bifurcation portion of a catheter assembly including a tube constraint according to one embodiment;

FIGS. 5A and 5B show various views of a catheter assembly including a tube constraint according to one embodiment;

FIGS. 6A-6D show suture wings including tube constraints according to possible embodiments;

FIG. 7 shows a cross sectional view of a bifurcation portion of a catheter assembly according to one embodiment;

FIG. 8 is a side view of a tube constraint for a catheter assembly according to one embodiment;

FIG. 9 is a side view of a tube constraint for a catheter assembly according to one embodiment; and

FIG. 10 is a side view of a tube constraint for a catheter assembly according to one embodiment.

DETAILED DESCRIPTION OF SELECTED EMBODIMENTS

Reference will now be made to figures wherein like structures will be provided with like reference designations. It is understood that the drawings are diagrammatic and schematic representations of exemplary embodiments of the present invention, and are neither limiting nor necessarily drawn to scale.

For clarity it is to be understood that the word “proximal” refers to a direction relatively closer to a clinician using the device to be described herein, while the word “distal” refers to a direction relatively further from the clinician. For example, the end of a catheter placed within the body of a patient is considered a distal end of the catheter, while the catheter end remaining outside the body is a proximal end of the catheter. Also, the words “including,” “has,” and “having,” as used herein, including the claims, shall have the same meaning as the word “comprising.”

Embodiments of the present invention are generally directed to the formation of a pre-curved catheter tube or other elongate medical device using the heat produced in heat sterilization procedures commonly used to sterilize medical devices prior to use. Pre-curving of the catheter tube is desirable to impart to the catheter assembly a desired positional configuration when the catheter assembly is inserted into a patient. Examples of catheter assemblies include CVC, PICC, dialysis, peripheral IV and other catheters, though the principles to be described herein can be applied to catheters and elongate medical devices of a variety of configurations.

Reference is first made to FIG. 1, which shows a catheter assembly (“catheter”) 10 configured in accordance with one embodiment. As shown, the catheter assembly (“catheter”) 10 includes an elongate catheter tube 12 that defines one or more lumens longitudinally extending between a proximal end 12A and a distal end 12B of the tube. A bifurcation 14 mates with the catheter tube 12 at the proximal end 12A thereof to provide fluid communication between the catheter tube and one or more extension legs 18.

A suture wing 16 is included with the bifurcation 14 for enabling suturing of the catheter assembly 10 to the patient's skin or other location. Though shown here as a discrete portion of the bifurcation, the suture wing in other embodiments can be integrally formed with the bifurcation.

FIGS. 1A and 1B show that the catheter tube 12 is compliant and is disposed in a pre-curved configuration, wherein the tube crosses over itself or over another part of the catheter assembly. This is also referred to herein as an “alphacurve” configuration. In addition to an alphacurve or looped configuration, the catheter tube 12 can be bent or curved in a variety of other configurations. Note also, that, though shown and described herein in connection with medical applications for providing vascular access to a patient, the catheter assembly can be configured differently from what is shown and described herein for a variety of applications. For example, the principles to be taught herein can be applied to a variety of catheter types and configurations, including CVCs, PICCs, PIVs, drainage, feeding, urinary catheters, etc.

As shown in FIG. 1B and additionally illustrated in FIG. 2, the catheter further includes in the present embodiment a tube constraint 20 sized and configured to temporarily constrain the catheter tube 12 in a curved configuration (also referred to herein as a pre-curved configuration), such as that shown in FIG. 1B. Temporary maintenance of the catheter tube 12 in such a curved configuration enables the curve to be permanently set in the catheter tube—via subjecting the constrained catheter tube to a suitable heating procedure—even after the catheter tube is released from the tube constraint, thus desirably producing a pre-curved catheter, similar to that shown in FIG. 1A, which can be used for various medical applications.

The tube constraint 20 of FIG. 1B is shown in FIG. 2 to include notches 22 defined on both the bifurcation 14 and the suture wing 16. In an embodiment, and as best seen in FIG. 2, at least the bifurcation portion of the tube constraint may be mated with the catheter tube 12 such that it is permanently included with, or permanently attached to, the catheter assembly 10. In detail and as shown, an elongate, laterally extending notch 22A is defined in a base 16A of the suture wing while a corresponding notch 22B is defined on a bottom surface 14A of the bifurcation. When the suture wing 16 is rotatably attached to the bifurcation 14 via receipt of a distal portion of the bifurcation through a loop 16B of the suture wing, the notches 22A, 22B align such that a portion of the looped catheter tube 12 can be interposed between the notches in a sandwiched configuration in such a way as to securely hold yet not substantially compress the tube. This positional relationship maintains the catheter tube 12 in the looped configuration shown in FIG. 1B until the tube is removed from the notches 22A and 22B, as discussed below. As such, the notches 22A and 22B are suitably sized to perform the above functionality. In one embodiment, therefore, the notches can be sized according to the diameter size of the catheter tube, which size can vary as appreciated by one skilled in the art. In another embodiment, the notches are sized so as to provide more or less compression of the catheter tube, as may be desired. Note further that the suture wing 16 further includes a pair of holes 16C for enabling the passage of sutures therethrough in securing the catheter 10 to the patient's skin.

FIGS. 3A and 3B show that the notches 22A, 22B can be adjusted in position along the bodies of the suture wing 16 and the bifurcation 14 so as to provide different degrees of catheter tube bend. For instance, FIG. 3A shows the notches 22A and 22B disposed relatively more distally with respect to the structure of the catheter 10 so as to provide a relatively smaller radius of curvature for the looped catheter tube 12 when it is received within the notches. This in turn produces a relatively more tightly-looped curve in the catheter tube 12 after formation. In contrast, FIG. 3B shows the notches 22A and 22B disposed relatively more proximally with respect to the structure of the catheter 10 so as to provide a relatively larger radius of curvature for the looped catheter tube 12 when it is received within the notches. This in turn produces a relatively less tightly-looped curve in the catheter tube 12 after formation. Note that other locations on the catheter assembly 10 can be employed for fixing the catheter tube 12 in a looped configuration.

The looped or curved configuration of the catheter tube 12 discussed above is initially maintained by the tube constraint 20, e.g., the notches 22A, 22B, such as is seen in FIG. 1B. The constrained catheter tube 12 is then subjected to a heating procedure of sufficient time, temperature, and duration as to permanently set the curved configuration of the tube so as to resemble that shown in FIG. 1A, as desired.

In the present embodiment, a heat sterilization procedure to sanitize the catheter assembly before shipment to and use by customers occurs after catheter manufacture and further serves as the heating procedure to permanently set the curved configuration of the catheter tube 12 (FIG. 1A). Though other types of heat-based sterilizing procedures may be used, in the present embodiment an ethylene oxide (“ETO”) sterilization procedure is employed to sterilize the catheter 10. The heat produced during the ETO sterilization procedure is sufficient in the present embodiment to permanently set the catheter tube 12 in the curved configuration shown in FIG. 1A even after the tube is released from the tubing constraint 20 after the ETO sterilization procedures is complete. As mentioned, other heat-based sterilization or non-sterilizing heating procedures can be employed to impart to the catheter tube the curved configuration. Examples include steam sterilization, autoclaving, etc.

In the present embodiment, the catheter tube 12 and bifurcation 14 include an aliphatic polyether polyurethane sold under the name TECOFLEX®, by Lubrizol Advanced Materials, Inc. of Cleveland, Ohio, though other thermoplastics can also be acceptably employed from which the catheter tube is manufactured so as to impart a permanent curve to the catheter tube under heat sterilization or other suitable heating procedure. In one embodiment, a thermoplastic falling within a hardness range of between about 65 D and about 95 A can be used, though thermoplastics outside of this range can also be employed.

In light of the above and in connection with the presently discussed figures, in one embodiment the curved configuration can be permanently set in the catheter tube 12 by first manufacturing the catheter assembly 10 to include the components shown and described in connection with FIG. 1A, or more or fewer components as may be appreciated by one skilled in the art. The catheter tube 12 can then be placed in a curved (e.g., looped) configuration by placing a portion thereof into the tube constraint 20, e.g., the notches 22A, 22B (FIGS. 1B, 2) in the present embodiment, or other suitable tube constraint such that the curved configuration is temporarily maintained. The catheter assembly is then optionally packaged in a package or suitable container, and subsequently placed in a chamber where it is subjected to ETO or other suitable form of heat sterilization for a predetermined amount of time and temperature. This process permanently sets the curved configuration in the catheter tube 12. As mentioned, other suitable heating procedures can be used in place of ETO or other heat-based sterilization procedures. Though the catheter tube 12 can then be removed from the notches 22A, 22B that form the tube constraint 20 if desired, in another embodiment the catheter tube is left in the notches or other suitable tube constraint within the sealed and sterilized container until the catheter assembly 10 is removed by the clinician in preparation for insertion into the patient. Variations to this process are possible, as appreciated by one skilled in the art. Note that after the curve is permanently set and the catheter tube is removed from the tube constraint, a limited amount of relaxation of the catheter tube curve may occur. For instance, in one embodiment the catheter tube 12 as shown constrained in FIG. 1B may, after having its curve permanently set and being released from the tube constraint, relax to the shape shown in FIG. 1A.

In various prophetic examples, permanent curving of polyurethane CVC and PICC catheter tubes (including a bifurcation including a suture wing of low-density polyethylene (“LDPE”) or thermoplastic elastomer) via use of a tube constraint during ETO heat sterilization procedures are believed achievable at the following temperatures and time combinations: about 55 degrees Celsius (“C.”) for about 15 minutes; about 55 degrees C. for about one hour; about 55 degrees C. for about 12 hours; about 100 degrees C. for about 12 hrs; about 100 degrees C. for about one hour; about 100 degrees C. for about 15 minutes; about from about 220 to about 255 degrees Fahrenheit (“F.”) for about 65 to about 80 seconds; and from about 230 to about 240 degrees F. for about 270 to about 330 seconds. Note that the above examples, like typical ETO sterilization procedures, are performed under vacuum, though it is believed that the presence of a vacuum does not substantially affect the ability of the heating procedure to set the catheter tube in a permanent curved configuration. Generally, it is understood that permanent forming of the catheter tube in accordance with the present disclosure depends on several factors, including tube material, tube thickness, lumen geometry, etc. It is further appreciated that a wide variety of time and temperature combinations for the heating procedure are possible. Generally, relatively lower heating procedure temperatures will require relatively more time with the catheter tube constrained in its curved configuration during heating in order for the curve to be permanently set in the tube. Correspondingly, relatively higher heating procedure temperatures require relatively less time of constraint to set the curve during heating.

FIGS. 4A and 4B depict the tube constraint 20 according to another embodiment, wherein the tube constraint includes a notch 24 defined through the base 16A of the bifurcation suture wing 16. The notch 24 is sized so that a portion of the catheter tube 12 is retained thereby without constricting the tube portion. The notch 24 can be configured to have a break or open portion in its perimeter such that the catheter tube 12 can be pushed through the open portion into the notch. In another embodiment, the notch perimeter is completely closed off such that the distal end 12B of the catheter tube 12 must be first passed through the notch for the notch to receive the tube. Note that in the present embodiment the suture wing 16 is configured to swivel about the body of the bifurcation 14 such that the orientation of the curved portion of the catheter tube 12 can be adjusted according to the desired tube orientation once the curve is permanently set via the ETO heat sterilization or other suitable heating procedure.

FIG. 5 shows the tube constraint 20 according to yet another embodiment, wherein the tube constraint includes a form 28 that is shaped and configured to constrain a portion of the catheter tube 12 in a curved configuration in preparation for permanent forming of the curve via ETO sterilization or other suitable heating procedure. As shown, the form 28 includes a relatively flat, compliant body 28A including a suitably strong material, such as paper, fiberboard, cardstock, cardboard, etc. In one embodiment, the form 28 includes a durable spun-bonded olefin sheet sold under the trademark TYVEK® by E. I. du Pont de Nemours and Co., though various other suitable materials can also be employed.

The form body 28A defines two hooked segments 30 that engage portions of the catheter assembly 10: one to wrap about a proximal portion of the catheter tube 12; the other to wrap about one of the extension legs 18. The form body 28A further defines two holes 32 through which a portion of the curved catheter tube passes. The holes 32 are sized so as to suitable restrain the catheter tube 12, thus enabling the form 28 to temporarily maintain the tube in a desired curved configuration. Once the catheter tube 12 has been subjected to a suitable heating procedure to permanently set the curve thereof, the form 28 can be removed from the catheter assembly 10 as desired. In one embodiment, instructions are printed on the form 28 or otherwise provided to assist the user in removing and/or disposing of the form. In one embodiment, the form 28 can be configured such that it can be ripped/cut apart to remove it from the catheter assembly 10. For instance, form in one embodiment can include perforations to ease removal from the catheter assembly. Note that the particular shape, size, and configuration of the form can vary from what is shown and described herein.

FIGS. 6A-6D depict details of the tube constraint 20 according to yet another embodiment, wherein the tube constraint includes a clip 34 disposed on a portion of the suture wing 16 and sized to temporarily retain therein a portion of the catheter tube 12 in the curved configuration. As illustrated, the clip 34 can be variously positioned on the suture wing 16 or other catheter-related component, such as the main body of the bifurcation and can be removable in one embodiment. In particular, FIG. 6A shows the clip 34 extending from the base 16A of the suture wing 16 in such a way as to constrain the catheter tube 12 as shown in FIG. 6B. In contrast, FIGS. 6C and 6D show the clip extending from a portion of the loop 16B of the suture wing 16. Note that various other positional placements of the clip 34 are possible, both on the suture wing or bifurcation, or elsewhere on the catheter assembly 10.

FIG. 7 depicts details of the tube constraint 20 according to yet another embodiment, wherein the tube constraint includes a chamfered pocket 36 that can be included in the design of the base 16A of the suture wing 16. The chamfered pocket 36 is configured so as to facilitate ease of insertion into the pocket of a portion of the catheter tube 12 without negatively affecting the retention force needed to retain the tube therein. The particular angle of the chamfer or other configuration of the pocket 36 can vary from what is shown and described herein.

FIGS. 8-10 depict details of the tube constraint 20 according to yet other embodiments. In particular, FIG. 8 shows the tube constraint 20 as including an attachment piece 40, which in turn includes a body 42 that defines a clip portion 44 that is configured to receive therein a portion of the catheter tube 12 in order to hold it in a curved configuration. The attachment piece 40 further includes pegs 46 sized and configured to be received within the holes 16C of the suture wing 16 of the catheter assembly 10 (FIGS. 1A, 1B, 2) so as to temporarily secure the attachment piece in place with the catheter assembly. When forming of the catheter tube 12 is complete, the attachment piece 40 can be removed from the catheter assembly and discarded. The pegs 46 are sized to provide a removable interference fit with the suture wing holes 16C, in one embodiment. In other embodiments, other solutions for securing the attachment piece to the catheter assembly can be provided.

FIG. 9 depicts details of the tube constraint 20 according to yet another embodiment, wherein the tube constraint includes an attachment piece 50, which in turn includes a body 52 that defines a hole 54 that is configured to receive therethrough a portion of the catheter tube 12 in order to hold it in a curved configuration. The attachment piece 50 further includes a peg 56 sized and configured to be received within one of the holes 16C of the suture wing 16 of the catheter assembly 10 (FIGS. 1A, 1B, 2) so as to temporarily secure the attachment piece in place with the catheter assembly. When forming of the catheter tube 12 is complete, the attachment piece 50 can be removed from the catheter assembly and discarded. The peg 56 is sized to provide a removable interference fit with the suture wing holes 16C, in one embodiment. In other embodiments, other solutions for securing the attachment piece to the catheter assembly can be provided.

FIG. 10 depicts details of the tube constraint 20 according to yet another embodiment, wherein the tube constraint includes an attachment piece 60, which in turn includes a body 62 that defines a loop portion 64 that is configured to receive therethrough a portion of the catheter tube 12 in order to hold it in a curved configuration. The attachment piece 60 further includes a peg 66 sized and configured to be received within one of the holes 16C of the suture wing 16 of the catheter assembly 10 (FIGS. 1A, 1B, 2) so as to temporarily secure the attachment piece in place with the catheter assembly. When forming of the catheter tube 12 is complete, the attachment piece 60 can be removed from the catheter assembly and discarded. The peg 66 is sized to provide a removable interference fit with the suture wing holes 16C, in one embodiment. In other embodiments, other solutions for securing the attachment piece to the catheter assembly can be provided. Note that, in the embodiments of FIGS. 8-10, other solutions for attaching to the catheter tube, apart from holes, clips, and loops, could be used and that these components can be interchanged between the designs shown in FIGS. 8-10. In yet another embodiment, a dual-clip device can be employed, wherein a first clip attaches to a first portion of the catheter tube and a second clip attaches to a second portion of the catheter tube to maintain the catheter tube in a curved, e.g., a looped, configuration.

In addition the above embodiments, other tubing constraint configurations for retaining the catheter tube in a pre-curved configuration can be employed, including a portion of adhesive including a glue dot or adhesive tape, a feature included with the catheter assembly container, a silicone insert, a removable clip, etc. In one embodiment the tube constraint 20 prevents the catheter tube 12 from coming into contact with another portion of the tube or other like-material components, such as the body of the bifurcation 14, so as to avoid knitting of the two components together during heat-based sterilization. Also, the tubing constraint is configured in one embodiment to hold the catheter tube without damaging or deforming it.

Embodiments of the invention may be embodied in other specific forms without departing from the spirit of the present disclosure. The described embodiments are to be considered in all respects only as illustrative, not restrictive. The scope of the embodiments is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. 

What is claimed is:
 1. A catheter assembly, comprising: an elongate catheter tube defining at least one lumen; and a tube constraint permanently included with the catheter assembly that temporarily constrains a portion of the catheter tube during a heating procedure of the catheter assembly to create a curved portion of the catheter tube, the curved portion of the catheter tube maintaining a permanent curved configuration after the heating procedure is complete and the portion of the catheter tube is released from the tube constraint, the tube constraint to remain coupled to the catheter assembly after the portion of the catheter tube is released from the tube constraint.
 2. The catheter assembly as defined in claim 1, wherein the heating procedure includes a heat sterilization procedure.
 3. The catheter assembly as defined in claim 2, wherein the heating procedure includes an ethylene oxide sterilization procedure.
 4. The catheter assembly as defined in claim 3, wherein the ethylene oxide sterilization procedure is performed at a temperature of at least about 55 degrees Celsius.
 5. The catheter assembly as defined in claim 4, wherein the ethylene oxide sterilization procedure is performed for a time of at least about 15 minutes.
 6. The catheter assembly as defined in claim 1, wherein the curved configuration includes a looped configuration of the catheter tube.
 7. The catheter assembly as defined in claim 1, wherein at least part of the tube constraint is detachable from the catheter assembly.
 8. The catheter assembly as defined in claim 1, wherein when the curved portion of the catheter tube is retained by the tube constraint, the tube constraint prevents the curved portion of the catheter tube retained by the tube constraint from physically contacting another portion of the catheter tube.
 9. The catheter assembly as defined in claim 1, wherein the tube constraint includes at least one of a bifurcation and a suture wing.
 10. The catheter assembly as defined in claim 9, wherein the tube constraint includes a first notch disposed on the suture wing and a second notch disposed on the bifurcation such that a portion of the catheter tube is interposed between the first and second notches in a sandwich configuration when the catheter tube is in the curved configuration.
 11. The catheter assembly as defined in claim 10, wherein a position of the first and second notches is predetermined so as to place the catheter tube in the curved configuration that defines a predetermined radius.
 12. The catheter assembly as defined in claim 1, wherein the tube constraint includes a compliant form including at least one portion for attaching to the catheter assembly and at least one hole for receiving therethrough the portion of the catheter tube for maintaining the curved portion of the catheter tube in the curved configuration.
 13. The catheter assembly as defined in claim 12, wherein the tube constraint includes a spun-bonded olefin sheet.
 14. The catheter assembly as defined in claim 1, wherein the tube constraint includes at least one clip disposed on at least one of a bifurcation and a suture wing of the catheter assembly.
 15. The catheter assembly as defined in claim 1, wherein the tube constraint includes an adhesive material temporarily attached to a portion of the catheter assembly.
 16. The catheter assembly as defined in claim 1, wherein the curved portion of the catheter tube is distal of the tube constraint.
 17. A catheter assembly, comprising: an elongate catheter tube defining at least one lumen; a bifurcation operably connecting the elongate catheter tube to at least one extension leg tube; and a tube constraint permanently included in the bifurcation, the tube constraint temporarily constraining the catheter tube in a curved configuration during a heating procedure of the catheter assembly, the heating procedure imparting a permanent curve to the catheter tube after the catheter tube is released from the tube constraint.
 18. The catheter assembly as defined in claim 17, wherein the catheter assembly further includes a suture wing and wherein the suture wing includes a first notch and the bifurcation includes a second notch such that a portion of the catheter tube is interposed between the first and second notches in a sandwiched configuration when the catheter tube is in the curved configuration.
 19. The catheter assembly as defined in claim 18, wherein the permanent curve of the catheter tube defines a loop.
 20. The catheter assembly as defined in claim 18, wherein the suture wing is rotatably attached to the bifurcation and wherein the first notch is laterally defined across a base of the suture wing.
 21. The catheter assembly as defined in claim 17, wherein the heating procedure includes an ethylene oxide heat sterilization procedure.
 22. The catheter assembly as defined in claim 21, wherein the ethylene oxide sterilization procedure is performed in a substantial vacuum at a temperature of at least about 55 degrees Celsius for a time of at least about 15 minutes.
 23. The catheter assembly as defined in claim 17, wherein the tube constraint is proximal of the permanent curve of the catheter tube.
 24. The catheter assembly as defined in claim 17, wherein the permanent curve of the catheter tube is distal of the bifurcation. 